FOREWORD RM029E RM027E RM036E EWD013E. M/Y Version. M/Y Version BRM002E 36438E

Transcription

1 FOREWORD 1 This repair manual has been prepared to provide information on the repair methods (including cutting and welding operations, but excluding painting) recommended by TOYOTA for collision damaged body components of the TOYOTA SUPRA. Applicable models: MA70 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, tools, equipment, etc. However, it should be noted that the front fenders of all TOYOTA models are bolted on and require no welding. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the service of specifications and repair procedures other than collision damaged body components of the TOYOTA SUPRA, refer to the following repair manuals. Manual Name 7M GE Engine Repair Manual TOYOTA SUPRA Chassis and Body Repair Manual TOYOTA SUPRA Chassis and Body Repair Manual Supplement TOYOTA SUPRA Electrical Wiring Diagram Manual TOYOTA SUPRA Repair Manual (USA and Canada) TOYOTA SUPRA Electrical Wiring Diagram Manual (USA and Canada) Fundamental Body Repair Procedures Fundamental Painting Procedures Pub. No. RM029E RM027E RM036E EWD013E M/Y Version M/Y Version BRM002E 36438E All information contained in this manual is the most up to date at the time of publication. However, specifications and procedures are subject to change without prior notice. TOYOTA MOTOR CORPORATION

2 IN-2 HOW TO USE THIS MANUAL INTRODUCTION Each repair method description provided in Section RE of this manual comprises two pages, divided into 2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair. RE 26 BODY PANEL REPLACEMENT Rear Body Components QUARTER PANEL (CUT) REMOVAL 80 mm Cut and Join Location 200 mm Cut and Join Location [Cut and Join Location] Front Rear Braze 1. Cut and join the quarter panel as shown above. mm in REPLACEMENT PART AND METHOD QUARTER PANEL (CUT) Replacement method (ASSY)..... Assembly replacement (CUT) Major cutting (less than 1/2 of part used) (CUT H).... Half cutting (about 1/2 of part used) (CUT P).... Partial cutting (most of part used) Replacement part BODY VARIATIONS AND PART LOCATION Body variations: Non.... All models REMOVAL DIAGRAM Describes in detail removal of the damaged part involving repair by cutting. REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal.

3 INTRODUCTION IN-3 BODY PANEL REPLACEMENT Rear Body Components RE 27 INSTALLATION Butt Weld Butt Weld Body Sealer Braze Body Sealer About 5 mm mm in Before temporarily installing the new part, apply body sealer to the wheel arch portion. NOTE: 1) Apply sealer approx. 5 mm (0.20 in.) from the flange, avoiding any oozing. 2) Apply evenly, approx. 3 4 mm ( in.) in diameter. 3) For other sealing points, refer to section SU. 2. Temporarily installing the new part and check the fit of the front door, luggage compartment door and rear combination lamp. INSTALLATION DIAGRAM Describes in detail installation of the new part involving repair by welding and/or cutting, but excluding painting. INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation. SYMBOLS See page IN 4. ILLUSTRATION OF WELD POINT Weld method and panel position symbols. See page IN 5.

4 IN-4 INTRODUCTION SYMBOLS The following symbols are used in the welding Diagrams in Section RE of this manual to indicate cutting areas and the types of weld required. SYMBOLS MEANING ILLUSTRATION SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN 5) CONTINUOUS MIG WELD (BUTT WELD OR TACK WELD) BRAZE BODY SEALER

5 INTRODUCTION IN-5 Illustration of Weld Point Symbols EXAMPLE: REMOVAL INSTALLATION Weld points Remove weld point and panel position Weld points Weld method and panel position SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION Remove Weld Points Spot Weld (Outside) (Middle) Mig Plug Weld (Inside) HINT: Panel position syrnbols are as seen from the working posture. Spot MIG Weld

6 IN-6 INTRODUCTION GENERAL REPAIR INSTRUCTIONS Work Precautions SAFETY Never stand in direct line with the chain when using a puller an the body or frame, and be sure to attach a safety cable. VEHICLE PROTECTION When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire proof covers. SAFETY 1. Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. 2. If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line. Glass Cover WRONG Safety Cable Seat Cover WRONG SAFETY WORK CLOTHES In addition to the usual mechanic wear, cap and Safety shoes, the necessary gloves, head protector, glasses, ear plugs, face protector, dust prevention mask, etc. should be worn as the situation demands. Dust Prevention Mask Face Protector Welder s Glasses Ear Plugs SAFETY Before performing repair work, disconnect the battery cables. Body Mechanic Stand Head Protector Safety Shoes Welder s Gloves Cotton Gloves HAND TOOLS Keeping your hand tools in neat order will have an effect on your work efficiency.

7 INTRODUCTION IN-7 Proper and Efficient Work Procedures REMOVAL PRE REMOVAL MEASURING Before removal or cutting operations, take measurements in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame. REMOVAL. OF ADJACENT COMPONENTS When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. CAUTION: 1. Be especially careful not to damage screw or clip holes. 2. If the paint is accidently scratched, apply touch up paint immediately. Even the slightest scratch may result in corrosion or appearance of rust. NO. OF SPOT WELDS Make a note of the number of spot welds for later reference. NOTE: The number of spot welds may vary depending on the vehicle. PRECAUTIONS FOR DRILLING OR CUTTING Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged. WRONG REMOVAL OF ADJACENT PARTS When removing adjacent parts by avoid accidental marring, etc., wrapping the tools used and surrounding body parts in protective tape. NOTE: 1) Take particular care not to damage any screw or clip holes. 2) If you do scratch a painted surface, retouch immediatly after. Even a small scratch will result in rust and corrosion. CUTTING AREA Always cut in a straight line and avoid reinforced areas. Cutting Okay Reinforcement Corners

8 IN-8 INSTALLATION PRE WELDING MEASUREMENTS Always take measurements before installing underbody or engine components to insure correct assembly. After installation, confirm proper fit. INTRODUCTION WELDING PRECAUTIONS 1. The number of welding spots should be as follows. Spot weld: 1.3 x No. of manufacturer s spots. Plug weld: More than No. of manufacturer s plugs. POST WELDING REFINISH- ING 1. Always check the welded spots to insure they are secure. 2. When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld. OKAY WRONG 2. Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. OKAY Seal WRONG Safety Glass Body Measurement Diagrams SPOT WELD LOCATIONS Try to avoid welding over previous spots. Old Spot Locations New Spot Locations SPOT WELDING PRECAUTIONS 1. The shape of the welding tip point has an effect on the strength of the weld. 2. Always insure that the seams and welding tip are free of paint. Tip Cutter

9 INTRODUCTION IN-9 PREPARATION FOR INSTALLATION SPOT WELD POINTS Less than 3 mm When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. NOTE: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick. APPLICATION OF WELD THROUGH PRIMER For treatment against corrosion, remove the paint from the portion of the new part and body to be welded, and apply weld through primer. Air Saw WRONG mm Puncher Overlap ROUGH CUTTING OF JOINTS For joint areas, rough cut the new part, leaving mm ( in.) overlap. MAKING HOLES FOR PLUG WELDING For areas where a spot welder cannot he used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) φ over 1.0 (0.04) over 6.5 (0.26) φ over

10 IN-10 INTRODUCTION ANTI CORROSIVE TREATMENT When replacing body panels, always apply body sealer, anti rust treatment or undercoating according to the requirements of your country. BODY SEALER Apply body sealer to the required areas. CHASSIS RUST PROOFING Anti rust treatment for welding spots or inside brazed areas (torque box). Cartridge Type Tube Type Nozzle Air Gun UNDERCOATING Anti rust treatment for underbody welding spots and wheel housings. Undercoating (Oil base) Undercoating (Water base) Spray Gun

11 INTRODUCTION IN-11 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front Center of front suspension crossmember Rear Center of differential carrier PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand IN0088 IN0089

12 IN-12 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. Assy, assy Assembly, assembly Sub assy Sub assembly Ex. Except in. Inch IRS Independent Rear Suspension 4 link 4 link Rear Suspension MIG Metal Inert Gas M/Y Model Year OPN Operation SP Spot Weld (Resistance Spot Weld) w/ With w/o Without FR Front RR Rear RH Right hand RHD Right hand Drive LH Left hand LHD Left hand Drive

13 TE-2 TOOLS AND EQUIPMENT MEASURING INSTRUMENTS For measuring body dimensions Tracking Gauge Frame Centering Gauge When 3 or 4 are used together, measurements of twists, bends or warps in the body and frame are possible. SEPARATING TOOLS For separating spot welds and making holes in the body. Air powered Drill Electric powered Drill For separating spot welds and making holes in the body. For separating spot welds. Spot Cutter For cutting panels. Air powered Cutter For separating spot and plug welds and grinding off traces of plug welds. Air powered Chuck Grinder

14 TOOLS AND EQUIPMENT TE-3 SEPARATING TOOLS (Cont d) For rough cutting and rough flattening of panels. Air powered Chisel Panel Cutter For rough cutting of panels. Flat Chisel For separating spot welds. Hammer Tool For rough flattening in hard to reach areas. For rough cutting of pillars, rocker panels, etc. Air powered Saw For rough cutting of pillars, rocker panels, etc. Air powered Saw For rough cutting of pillars, rocker panels, etc. Hacksaw

15 TE-4 TOOLS AND EQUIPMENT INSTALLATION ASSISTANCE TOOLS For temporary installation of panels and holding of portions to be welded. Vise Grip Wrench For making flanges in overlapping panels. Flanging Tool For hemming door outer panels, etc. Hemming Tool For making holes for MIG plug welding. Hole Punch BODY PROTECTORS For protecting the seats from welding sparks, etc. Seat Cover For protecting the glass from welding sparks, etc. Glass Cover

16 TOOLS AND EQUIPMENT TE-5 WELDING INSTRUMENTS For panel welding. MIG Welder (Metal Inert Gas) For panel welding. Spot Welder For rough cutting of panels, members, etc. Gas Welder Torch Gas Cutter Torch For soldering and peeling of paint. Acetylene Gas Torch For straightening distorted panels. Straightening Machine For extraction of closed in panels. Panel Extractor

17 TE-6 TOOLS AND EQUIPMENT LIGHT BODY REPAIR TOOLS For straightening lightly damaged panels. Body Pullers GRINDING AND POLISHING TOOLS For grinding plug welds, butt welds and door hems. Air powered Disc Grinder For grinding plug welds, butt welds and door hems. Electric powered Disc Sander For removing paint around weld areas. Belt Sander For rough grinding and polishing, and feather edging. Double action Sander

18 TOOLS AND EQUIPMENT TE-7 GRINDING AND POLISHING TOOLS (Cont d) For rough polishing of panel putty. Straight line Sander Air powered Orbital Sander For removing putty over a wide area, resurfacing and refinishing. For peeling paint. Air powered Disc Sander For paint removal. File Holder Flexible File Holder For correction of soldering spots and resurfacing of panels. For rough finishing of panels. Surforrn Tool

19 DI-2 BODY DIMENSIONS Three dimensional distance Center to center straight line distance GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (Three dimensional distance) Straight line distance between the centers of two measuring points. Two dimensional distance Vertical distance in center Center to center Horizontal distance in forward/rearward Imaginary Standard Line Vertical distance in lower surface (b) (c) (Two dimensional distance) Horizontal distance in forward/rearward between the centers of two measuring points. The height from an imaginary standard line. In cases in which only one dimension is given, left and right are symmetrical. The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. Plate Looseness Body Looseness Pointer Looseness Pointer 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. Master Gauge Wrong Pointer Correct HINT: 1. The height of the left and right pointers must be equal. 2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3. Take care not to drop the tracking gauge or otherwise shock it. 4. Confirm that the pointers are securely in the holes. Along Body Surface Front Spring Support Inner Hole Tape Measure Front Suspension Member Rear Side Upper Installation Hole (c) (d) When using a tape measure, avoid twists and bends in the tape. When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface.

20 BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT mm (in.) Symbol Nomenclature Hole dia. A, a Front fender installation nut front 8 (0.31) B, b Front spring support hole rear 11 (0.43) C, c Front fender installation nut rear 8 (0.31) D Cowl top panel center mark E, e Front side member standard hole 15 (0.59) F, f Suspension member rear installation hole upper 17 (0.67) G, g Retractable light bracket installation nut upper 11 (0.43) H, h Radiator seal installation hole lower 7 (0.28) I, i Front fonder aide installation hole 8 (0.31) J, j Cowl top panel standard hole 10 (0.39) K Hood lock support brace installation nut 7 (0.28) BO1788

21 BODY DIMENSIONS DI-3 LUGGAGE COMPARTMENT X, x Point Front mm (in.) Symbol Nomenclature Hole dia. V Back door opening frame center mark 2 (0.08) W, w Rear suspension spring support hole inner 9 (0.35) X, x Rear floor pan bumper installation hole front 40 (1.57) BO1790

22 UNDER BODY BO1789 Symbol L I M, m N, n O,o P, p Nomenclature Front side member bumper front installation hole Lower Front side member bumper front installation hole Lower Stabilizer front installation nut Suspension member front installation hole lower Suspension member rear installation hole lower Front floor under reinforcement standard hole Hole dia 15 (0.59) ( ) 11 (0.43) 17 (0.67) 17 (0.67) 10 (0.39) Symbol Q,q R, r S, s T, t U, u Wheel base 2,595 (102.17) Nomenclature Front floor No. 2 reinforcement standard hole Suspension member front installation hole outer Center floor side member standard hole Suspension member rear installation hole Rear floor side member standard hole Imaginary Standard line mm (in) Hole dia. 10 (0.39) 19 (0.75) 18 (0.71) 25 18( ) 18 (0.71) BODY DIMENSIONS DI-3

23 CN-2 BODY PANEL CONSTRUCTION STANDARD BODY MARKS LIFTBACK mm in φ 0.39 Center Mark Assembly Mark Center Mark (7φ) Center Mark 2R Assembly Mark Assembly Mark l0φ l0φ l0φ Assembly Mark Assembly Mark l0φ

24 BODY PANEL CONSTRUCTION CN-3 HIGH STRENGTH STEEL (HSS) PARTS Generally, High Strength Steel (HSS) is that which has an intensity value of at least 35 kg f/mm 2, and distinguished from mild steel. The handling of HSS is the same as for mild steel, but the following should be observed. 1. Panel Hammering; Because HSS is thinner than mild steel, care should be taken to avoid warping during hammering operations. 2. Removing Stop Welds: Because HSS is tougher than mild steel, damage will occur more easily to a regular drill. Therefore, an HSS Spot Cutter is recommended. Also, use a high torque drill at low speed, and supply grinding oil to the drill during use. 3. Panel Welding: Panel welding procedures for HSS are exactly the same as for mild steel. Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. Front Spring Support Plate Engine Hood Panel Hood Stopper Reinforcement Cowl Top to Apron Brace Front Body Pillar Upper Inner Reinforcement Quarter Wheel Housing No. 1 Gusset Back Door Upper Outer Panel Quarter Pillar Inner Reinforcement Back Door Lower Outer Panel Back Door Hinge Reinforcement Belt Anchor to Roof Side Inner Reinforcement Rear Suspension Spring Support Rear Floor Side Member Front Crossmember No. 2 Reinforcement Front side Member Front Apron to Cowl Side Upper Member Front Floor Under Reinforcement Front Body Outer Pillar Belt Anchor Reinforcement Rear Bumper Reinforcement Front Bumper Reinforcement Door Side Impact Protection Beam (USA, Canada, Saudi Arabia and Australia)

25 RE-2 BODY PANEL REPLACEMENT FRONT CROSSMEMBER (ASSY) REMOVAL

26 BODY PANEL REPLACEMENT RE-3 INSTALLATION 1. Temporarily installing the new part and measure each part in accordance with the body dimension diagram.

27 RE-4 BODY PANEL REPLACEMENT RADIATOR SUPPORT (ASSY) REMOVAL Cut the weld points from the back side.

28 BODY PANEL REPLACEMENT RE-5 INSTALLATION Assembly Mark 1. Temporarily install the new part with the assembly mark and measure each part in accordance with the body dimension diagram.

29 RE-6 BODY PANEL REPLACEMENT RADIATOR UPPER SUPPORT (ASSY) REMOVAL

30 BODY PANEL REPLACEMENT RE-7 INSTALLATION 1. Temporarily install the new part and measure each part in accordance with the body dimension diagram. NOTE: Install the new panel with the hood lock support.

31 RE-8 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REMOVAL

32 BODY PANEL REPLACEMENT RE-9 INSTALLATION Assembly Mark 1. Determine the installation position of the new part by the assembly mark. 2. Measurements must be accurate with the body dimension diagram, as this effects the front wheel alignment. NOTE: The position of the front spring support hole is very important 3. Check the fit of the front fender and hood.

33 RE-10 BODY PANEL REPLACEMENT FRONT FENDER APRON (CUT H) REMOVAL Rough Cut 1. After removing the spot welds, rough cut the front fender apron shown above.

34 BODY PANEL REPLACEMENT RE-11 INSTALLATION Cut for supply part Cut Location Cut Location 1. Cut the supply part shown above.

35 RE-12 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REMOVAL

36 BODY PANEL REPLACEMENT RE-13 INSTALLATION Assembly Mark Front Side Member Plate 1. Temporarily install the new part and measure each part in accordance with the body dimension diagram. NOTE: Make sure each measurement is correct, as this part effects the front wheel alignment.

37 RE-14 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (CUT P) REMOVAL Standard Hole (15φ) Cut Location Cut Location Standard Hole (15φ) 60 mm 20 mm NOTE: Be careful not to damage the reinforcement when cutting the side member. [USA and Canada] [Ex. USA and Canada] 1. Before cutting the side member, remove the battery carrier support. (LH only) 2. Cut the front side member as shown above. NOTE: Be careful not to damage the reinforcement when cutting the side member. mm in

38 BODY PANEL REPLACEMENT RE-15 INSTALLATION Cut for supply part Remove the remaining reinforcement from the supply part. Cut Location 70 mm Cut Location Reinforcement Reinforcement [USA and Canada] [Ex. USA and Canada] 20 mm mm in [USA and Canada] Butt Weld Butt Weld [Ex. USA and Canada] 1. Cut the supply part shown above. 3. Temporarily install the new member, measure each part in accordance with the body dimension diagram. NOTE: Cut the front side member and the reinforcement at the same place. 2. Remove the remaining reinforcement from the supply part. 4. After installing the new member, install the front side member plate. (See page RE 13) 5. After installing the new member, install the battery carrier support. (LH only)

39 RE-16 BODY PANEL REPLACEMENT COWL TOP SIDE PANEL (ASSY) REMOVAL Cut with disc sander etc.

40 BODY PANEL REPLACEMENT RE-17 INSTALLATION Assembly Mark Assembly Mark Tack Weld (20 mm each) mm in Determine the installation position of the new part by the assembly mark. 2. Temporarily installing the new part and measure each part in accordance with the body dimension diagram.

41 RE-18 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REMOVAL 150 mm or more [Cut and Join Location] Cut and Join Location Cut With Disc Sander etc. 1. Cut and join the front body pillar at the location shown above. NOTE: 1) As shown above, cut and join the front body pillar outer and inner panels at a position shifted about 50 mm (1.97 in.). 2. Remove the remaining roof drip channel from body side. mm in

42 BODY PANEL REPLACEMENT RE-19 INSTALLATION Butt Weld [Reference] (mm) Tack Weld (20 mm each) 1. Temporarily install the new part and check the fit of the front door, front fender, hood and windshield glass. mm in , , ,

43 RE-20 BODY PANEL REPLACEMENT OUTER ROCKER PANEL (CUT) REMOVAL 140 mm Cut and Join Location [Cut and Join Location] mm in Cut and join the outer panel at the area as show above.

44 BODY PANEL REPLACEMENT RE-21 INSTALLATION Butt Weld 1. Temporarily install the new panel and check the fit for the front door and front fender. 2. There will be less warp if the cut edge (30 40 mm or in.) is adhered to the matching part before welding. NOTE: Scrape off the film on the cut edge and apply weld through primer to adhere the matching part.

45 RE-22 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) REMOVAL Arc Brazing (both sides) Braze (both sides) Braze (both sides) 1. Heat the brazed area of the front pillar and scrape off the brazing with a wire brush. NOTE: Be careful not to overheat the pillar. 2. Cut off the roof panel tip at the quarter panel are brazing connection with a cut grinder.

46 BODY PANEL REPLACEMENT RE-23 INSTALLATION Body Sealer (6 points) Braze (both sides) Body Sealer (8 points) Braze (both sides) 1. Before temporarily installing the new part, apply body sealer to the windshield header panel, roof panel center reinforcement and back window opening frame. NOTE: 1) Apply just enough sealer for the new part to make contact. 2) For other sealing points, refer to section SU. 2. Braze the front body pillar connection. NOTE: Before performing these operations, place a wet rag on the roof panel to protect it from damage.

47 RE-24 BODY PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ASSY) REMOVAL Hemming Location Heat slightly (USA, Canada, Saudi Arabia and Australia) Disc Sander 1. Grind out the hemming location, and remove the outer panel. 2. Slightly heating the outer panel will soften the sealer and make removal easier. (USA, Canada, Saudi Arabia and Australia).

48 BODY PANEL REPLACEMENT RE-25 INSTALLATION Assembly Mark Assembly Mark About 10 mm Body Sealer Body Sealer (6 points) (USA, Canada, Saudi Arabia and Australia) Do not close the drain hole. Cloth Tape 30 Hemming Tool mm in Before temporarily installing the new part, coat the back side of the new panel with body sealer. NOTE: 1) Coat evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter 2) For other sealing points, refer to section SU. 3) Determine the position for the new panel by the assembly marks. 3. Bend the flange hem approx. 30 with a hammer and dolly. Then use a hemming tool. NOTE: 1) Perform hemming in three steps, being careful not to warp the panel. 2) It a hemming tool cannot be used, hem with a hammer and dolly.

49 RE-26 BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REMOVAL 80 mm Cut and Join Location 200 mm Cut and Join Location [Cut and Join Location] Front Rear Braze 1. Cut and join the quarter panel as shown above. mm in

50 BODY PANEL REPLACEMENT RE-27 INSTALLATION Butt Weld Butt Weld Body Sealer Braze Body Sealer About 5 mm mm in Before temporarily installing the new part, apply body sealer to the wheel arch portion. NOTE: 1) Apply sealer approx. 5 mm (0.20 in.) from the flange, avoiding any oozing. 2) Apply evenly, approx. 3 4 mm ( in.) in diameter. 3) For other sealing points, refer to section SU. 2. Temporarily install the new part and check the fit of the front door, luggage compartment door and rear combination lamp.

51 RE-28 BODY PANEL REPLACEMENT QUARTER PANEL (CUT P) REMOVAL About 335 mm Cut and Joint Location Cut and Joint Location * This section is a cut and join location only. Refer to RE 26 for weld points. 1. Cut on the line shown above.

52 BODY PANEL REPLACEMENT RE-29 INSTALLATION Butt Weld After butt welding, apply body sealer Body Sealer Body Sealer Butt Weld About 5 mm * This section is a cut and join location only. Refer to RE 27 for weld points. 1. Before cutting the overlap areas, check the fit for the luggage compartment door and rear combination lamp. 2. Before welding, apply body sealer from inside of the vehicle. NOTE: 1) Do not apply body sealer to the weld seams before welding as the sealer will melt, resulting in a bad seal and a bad weld. 2) For other sealing points, refer to section SU. 3. Surface finish the weld seam from the inside also. NOTE: Be careful not to grind off to much weld as it will result in loss of durability.

53 RE-30 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY) REMOVAL Braze (both sides) (both sides) (both sides)

54 BODY PANEL REPLACEMENT RE-31 INSTALLATION Braze (both sides) (both sides) (both sides) 1. Temporarily install the new part and check the fit of the back door and rear combination lamp.

55 RE-32 BODY PANEL REPLACEMENT QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REMOVAL Roof Side Inner to Wheel Housing Brace 1. Before removing the quarter wheel housing outer panel, remove the roof side inner to wheel housing brace.

56 BODY PANEL REPLACEMENT RE-33 INSTALLATION Assembly Mark Assembly Mark 1. Determine the position of the new part by the assembly marks of the inner and outer panels. 2. Before welding the new part, temporarily install the quarter panel and check the fit.

57 RE-34 BODY PANEL REPLACEMENT REAR FLOOR PAN (CUT) REMOVAL Cut Location (LH) (RH) 1. Cut and join the rear floor pan shown above. 2. Avoid the rear floor side member. 3. Since each bracket is supplied separated, remove the brackets if reusing.

58 BODY PANEL REPLACEMENT RE-35 INSTALLATION Cut Locations Adhere Plug Weld New Part Body Sealer 1. Cut the new panel shown above. 2. Match the bracket to the new part location (dent marks) and install. 3. After temporarily installing the new part, measure each part in accordance with the body dimension diagram. 4. Plug weld the overlapping portion of the new part. NOTE: Be sure the portion to be welded are align and not loose. 5. Coat the overlapping opening portion from the both sides with body sealer.

59 RE-36 BODY PANEL REPLACEMENT REAR FLOOR SIDE MEMBER (ASSY) REMOVAL 1. Before removing the rear floor side member, remove the rear floor pan.

60 BODY PANEL REPLACEMENT RE-37 INSTALLATION 1. Temporarily install the new part and measure each part in accordance with the body dimension diagram.

61 RE-38 BODY PANEL REPLACEMENT CENTER FLOOR SIDE MEMBER (ASSY) REMOVAL

62 BODY PANEL REPLACEMENT RE-39 INSTALLATION Differential Support Member Mounting Reinforcement Quarter Wheel Housing No.1 Gusset Flexible Hose Bracket 1. Temporarily install the new part and measure each part in accordance with the body dimension diagram.

63 RE-40 BODY PANEL REPLACEMENT CENTER FLOOR NO. 2 CROSSMEMBER (ASSY) REMOVAL

64 BODY PANEL REPLACEMENT RE-41 INSTALLATION

65 PL-2 PART LISTS A A (RH) 53386A (LH) 53899B 55713A (RH) 55714A (LH) A (RH) 53724A (LH) 53287B (RH) 53288B (LH) C C Code Part Name Code Part Name Radiator Support Sub Assy 53723A 53724A Front Spring Support Reinforcement Radiator Upper Support Sub Assy Front Fender Sub Assy Hood Lock Brace Sub Assy B Front Fender Panel Support Front End Panel Mounting Bracket Front End Panel Sub Assy 53287B 53288B Radiator Support Extension Dash Panel Sub Assy Cowl Panel Sub Assy 53291C Radiator Support to Frame Seal 55713A Hood Sub Assy 55714A Cowl Top Side Panel 53385A 55748A Cowl Top Inner to Pillar Brace 53386A Hood Bumper Retainer 55748A Cowl Top Inner to Pillar Brace Hood Lock Control Cable Shield Front Crossmember Front Fender Apron Sub Assy

66 PART LISTS PL A 61625E 61766B (RH) 61748C (LH) 61631A (RH) 61632A (LH) 61773A A 61515A 61768B 61641B (RH) 61345B E 61767B (LH) A 61619A B 61633A (RH) 61634A (LH) 61774A A A B 61769A 61711A (RH) 61712A (LH) 61389A B (RH) 61658B (LH) 61617A (RH) 61618A (LH) Code Part Name Code Part Name Front Body Pillar Sub Assy Front Body Outer Pillar Sub Assy Roof Side Outer Rail Roof Side Inner Rail Roof Drip Channel 61345B 61346B 61347A 61348A A 61389A Center Body Inner Lower Pillar Belt Anchor to Center Pillar Reinforcement Belt Anchor to Center Pillar Lower Reinforcement Center Body Pillar End Plate Rocker Outer Panel 61515A Quarter Lock Pillar Extension 61619A 61625E 61626E 61631A 61632A 61633A 61634A 61641B 61642B 61657B 61658B 61675B A 61712A C 61766B 61767B Quarter Pillar Inner Reinforcement 61768B Quarter Panel 61617A 61618A Quarter Inner Rear Panel 61769A 61773A 61774A Quarter Panel Reinforcement Quarter Panel Inner Rear Extension Quarter Wheel Housing Outer Panel Quarter Wheel Housing Inner Panel Quarter Wheel Housing Gusset Quarter Panel End Lower Housing Rear Suspension Spring Support Reinforcement Quarter Inner Panel Sub Assy Roof Side Outer Reinforcement Roof Side Inner to Wheel Housing Brace Roof Side Inner to Wheel Housing Brace Reinforcement Belt Anchor to Roof Side Inner Rear Reinforcement Seat Belt Anchor No. 2 Reinforcement Back Door Opening Lower Patch

67 PL-4 PART LISTS 58102A B B 58311E 58313F A 58109A A C 57468A F 57656A C 57469A B 58207F 57467A 58101F 58101F 58208F A C 7466A A A B B B LHD B A A A

68 PART LISTS PL-5 Code Part Name Code Part Name Flexible Hose Bracket 57656A Exhaust Pipe Mounting No. 1 Bracket Rear Seat Back Hinge Mounting Bracket Front Side Member Rear Reinforcement Differential Support Member Mounting Reinforcement Torque Rod Rear Box Sub Assy Belt Anchor Reinforcement Sub Assy A Parking Brake Cable No. 1 Clamp Front Side Member Sub Assy 58101A Transmission Auxiliary Cover 57105A 58101F Mounting Floor No. 1 Bracket 57106A Front Side Member Plate Sub Assy A Front Floor Reinforcement Sub Assy Engine Rear Support Member Bracket 58109A Parking Brake Retainer Sub Assy Main Floor Side Member Sub Assy 57405A Center Floor No. 2 Crossmember Sub Assy Center Floor No. 1 Crossmember Sub Assy Front Floor Under Reinforcement Front Floor No. 2 Reinforcement Center Floor Side Member Front Floor Pan 58139A 58149A Front Floor Side Rear Plate Floor Side Member to Floor Pan Reinforcement Front Floor Stone Deflector Front Seat Mounting Inside Bracket Instrument Panel Brace Mounting Bracket 58207F 58208F Parking Brake Cable Clamp Sub Assy Front Floor Crossmember Center Floor Pan 57457C Front Outside Mounting Front Bracket 58212C Center Floor Front Pan Center Floor No. 3 Crossmember 58264B Parking Bake Cable Guide No. 1 Bracket Center Floor Crossmember Strength 58272B Belt Anchor to Floor Pan No. 4 Reinforcement 57465A 58273B Belt Anchor to Floor Pan No. 5 Reinforcement 57466A Center Floor Crossmember Rear Gusset 58275C Wire Harness Protector Bracket 57467A Front Seat Outside Mounting Front Bracket Spare Wheel Clam Bracket Sub Assy 57468A Body Lower Back Panel Sub Assy 57469A Front Seat Outside Rear Bracket 58311E Rear Floor Service Hole Cover Front Floor Crossmember Plate Rear Floor Pan Center Floor Crossmember Brace 58313F 58314F Rear Floor Pan to Quarter Panel Extension Rear Floor Side Member Sub Assy Rear Floor Heat Insulator Bracket 57631B 58364B Fuel Tank Support Bracket 57632B Rear Floor Side Member Front Reinforcement Fuel Tube Clamp Bracket Quarter Wheel Housing No. 1 Gusset

69 PL-6 PART LISTS A A (RH) (LH) (RH) (LH) Code Part Name Code Part Name 63102A Windshield Header Panel Sub Assy Front Door Panel Sub Assy Roof Panel Center Reinforcement Sub Assy 63105A Back Door Opening Frame Sub Assy Back Door Panel Sub Assy Roof Panel Front Door Outer Panel

70 PP-2 PLASTIC BODY PARTS HANDLING PRECAUTIONS 1. The repair procedure for plastic body parts must conform with the type of plastic material. 2. Plastic body parts are identified by the codes in the following chart. 3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting, etc.), consideration must given to the property of the plastic. Code Material Name Heat * Resisting Temperature C ( F) Resistance To Alcohol or Gasoline Notes AAS Acrylonitrile Acrylic Rubber Styrene Resin 80 (176) Alcohol is harmless if applied only for short time in small amounts (ex., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene Resin 80 (176) Alcohol is harmless if applied only for short time in small amounts (ex., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acrylonitrile Ethylene Rubber Styrene Resin 80 (176) Alcohol is harmless if applied only for short time in small amounts (ex., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene Rubber 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PC Poiycarbonate 120 (248) Alcohol is harmless. Avoid gasoline, brake fluid, wax, wax removers and organic solvents. PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. POM Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. * Temperature higher than those listed here may result in material deformation during repair.

71 PLASTIC BODY PARTS PP-3 Code Material Name Heat * Resisting Temperature C ( F) Resistance To Alcohol or Gasoline Notes PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for quick wiping to remove grease. PS Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PUR Thermosetting Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (ex., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (ex., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile Resin 80 (176) Alcohol is harmless if applied only for short time in small amounts (ex., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SMC Sheet Molding Compound 180 (356) Alcohol and gasoline are harmless. Avoid alkali TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (ex., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. * Temperature higher than those listed here may result in material deformation during repair.

72 PP-4 PLASTIC BODY PARTS LOCATION OF PLASTIC BODY PARTS Fuel Tank Filler Protector (PE) Safety Pad (PVC/PUR) Washer Nozzle (PA) Front Facia Cover (PUR) Roof Headlining (PVC/PUR) Quarter Ventilation Louver (ABS) Rear Spoiler (SMC) Fan Shroud (PP) Washer Jar (PP) *1 Rear Side Marker Lamp (PMMA/ ABS) Room Pressure Relief Valve (PP) Radiator Grill (ABS) Radiator Grill Lower (PP) Front Turn Signal Lamp (PMMA/PP) Fender Liner (PE) Fuel Tank No. 1 Protector (PE) Door Scuff Plate (PP) *1 Side Marker Lamp (PMMA/ABS) *2 Side Turn Signal Lamp (SAN/ABS) Front Bumper Cover (PUR) Front Spoiler Cover (PUR) NOTE: Resin material differs with model. / Made up of 2 or more kinds of materials. *1 USA and Canada *2 Except USA and Canada

73 PLASTIC BODY PARTS PP-5 Front Body Pillar Garnish (PUR) Roof Side Rail Front Garnish (PVC) Font Door Trim Board (PVC/PP) Speaker Door Grill (ABS) Roof Side Trim Garnish (ABS/PVC) Roof Headlining Rear Trim (PVC) Quarter Inside Trim Board (PVC/PP) Cowl Side Trim Board (PP) Back Door Trim Board (PP) Headlight Door (AAS) Speaker Box (PP) Radiator Reserve Tank (PP) Outer Rear View Mirror (ABS/TPU) Headlight Door Protector (PP) Speaker Box (PP) NOTE: Resin material differs with model. / Made up of 2 or more kinds of materials. *1 USA and Canada *2 Except USA and Canada

74 PP-6 PLASTIC BODY PARTS Deck Trim Side Jack Cover (PP) Cooler Unit (PP) Heater Blower (PP) Heater Unit (PP) Deck Side Trim Panel (PP) Rear Speaker Grill (PP/ABS) Deck Trim Rear Cover (PP) Deck Trim Side Service Hole Cover (PP) Font Fender Mud Guard (PUR) Outside Moudling (PVC/PUR) Rear Combination Lamp Service Cover (PP) License Pate Lamp (PMMA/PC) Side Mud Guard (PUR) Lower Back Finish Panel Hole Cover (ABS) Rear Bumper Cover (PUR) *1 Rear Marker Lamp (PMMA/ABS) Rear Combination Lamp (PMMA/AES) Quarter Panel Mud Guard (PUR) NOTE: Resin material differs with model. / Made up of 2 or more kinds of materials. *1 USA and Canada

75 SU-2 BODY PANEL SEALING AND UNDERCOATING BODY PANEL SEALING AREAS For water proofing and anti corrosion measures, always apply body sealer to the body panel seams and hems of the doors, hood, etc. NOTE: 1. Prior to applying body sealer, clean the area with a rag soaked in white gasoline. 2. If weld through primer was used, first wipe off any excess with thinner, and coat with anti corrosion primer before applying body sealer. 3. Wipe off any excess body sealer with a rag soaked in white gasoline. Flat Surfacing Flat Surfacing

76 BODY PANEL SEALING AND UNDERCOATING SU-3 After installing the plug hole, apply sealer. Flat Surfacing

77 SU-4 BODY PANEL SEALING AND UNDERCOATING Flat Surfacing

78 BODY PANEL SEALING AND UNDERCOATING SU-5 Hood Front Door Panel Do not close the drain hole. Back Door Panel Flat surfacing Fuel Inlet Box Fuel Inlet Box Cover

79 SU-6 BODY PANEL SEALING AND UNDERCOATING BODY PANEL UNDERCOATING AREAS To prevent corrosion and protect the body from damage by flying stones, always apply undercoating to the welded seams and wheel housings after chassis, under body or panel repair. NOTE: 1. First wipe off any dirt, grease or oil with white gasoline. 2. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately. 3. Do not coat parts which become hot, such as the tail pipe, or moving parts, such as the propeller shaft. 4. Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention. 5. Be sure to seal the edge of the flange of the member and bracket with undercoating. REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications for your country.